|Publication number||US7161810 B2|
|Application number||US 11/238,960|
|Publication date||Jan 9, 2007|
|Filing date||Sep 30, 2005|
|Priority date||Jan 30, 2003|
|Also published as||CA2455024A1, EP1443561A2, EP1443561A3, US7665207, US20060023439, US20060240594|
|Publication number||11238960, 238960, US 7161810 B2, US 7161810B2, US-B2-7161810, US7161810 B2, US7161810B2|
|Inventors||Lawrence R. Fraley, Voya Markovich|
|Original Assignee||Endicott Interconnect Technologies, Inc.|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (39), Non-Patent Citations (5), Referenced by (10), Classifications (82), Legal Events (12)|
|External Links: USPTO, USPTO Assignment, Espacenet|
This application is a continuation application of Ser. No. 10/661,616, filed Sep. 15, 2003, entitled “Stacked Chip Electronic Package Having Laminate Carrier And Method Of Making Same” (inventors: Lawrence Fraley et al), and now U.S. Pat. No. 6,992,896. Ser. No. 10/661,616 is a continuation-in-part of application Ser. No. 10/394,107, filed Mar. 24, 2003, entitled “Multi-Chip Electronic Package Having Laminate Carrier” (inventors: Lawrence Fraley et al), and now U.S. Pat. No. 7,035,113. Ser. No. 10/394,107 is a continuation-in-part of application Ser. No. 10/354,000, filed Jan. 30, 2003, entitled, “High Speed Circuit Board And Method For Fabrication” (inventors: Benson Chan et al), and now U.S. Pat. No. 6,828,514.
The present invention relates, in general, to an electronic package for mounting of integrated circuits, and in particular, to an organic, multi-layered laminated interconnect structure for use in such a package.
Organic laminate substrates, for example printed circuit boards and chip carriers, have been and continue to be developed for many applications. One such chip carrier is sold under the name HyperBGA by the assignee of this invention. (HyperBGA is a registered trademark of Endicott Interconnect Technologies, Inc.) These are expected to displace ceramic substrates in many chip carrier applications, because of reduced cost and enhanced electrical performance. The use of a multi-layered interconnect structure such as an organic, laminate chip carrier for interconnecting a semiconductor chip to a printed circuit board in an electronic package introduces many challenges, one of which is the reliability of the connection joints between the semiconductor chip and the organic chip carrier and another of which is the reliability of the connection joints between the organic chip carrier and the printed circuit board.
As semiconductor chip input/output (I/O) counts increase beyond the capability of peripheral lead devices and as the need for both semiconductor chip and printed circuit board miniaturization increases, area array interconnects are the preferred method for making large numbers of connections between a semiconductor chip and an organic chip carrier (such as the aforementioned HyperBGA chip carrier) and between the organic chip carrier and a printed circuit board. If the coefficient of thermal expansion (CTE) of the semiconductor chip, the organic chip carrier, and the printed circuit board are substantially different from one another, industry standard semiconductor chip array interconnections to the organic chip carrier can exhibit high stress during operation (thermal cycling). Similarly, the industry standard ball grid array (BGA) interconnections between the organic chip carrier and printed circuit board can also exhibit high stress during operation. Significant reliability concerns may then become manifest by failure of the connections or even failure of the integrity of the semiconductor chip (chip cracking). These reliability concerns significantly inhibit design flexibility. For example, semiconductor chip sizes may be limited or interconnect sizes, shapes and spacing may have to be customized beyond industry standards to reduce these stresses. These limitations may limit the electrical performance advantages of the organic electronic package or add significant cost to the electronic package. Typically a semiconductor chip has a CTE of 2–3 parts per million per degree Celsius (ppm/° C.) while a standard printed circuit board has a much greater CTE of 17–20 ppm/° C.
One example of an organic chip carrier designed to overcome such CTE and related problems is defined in U.S. Pat. No. 6,351,393 (J. S. Kresge et al) which includes a specific thermal internally conductive layer designed to prevent failure between the single chip and the carrier solder connections, and those between the carrier and base substrate (e.g., PCB) on which it is positioned. This patent is incorporated herein by reference.
Other examples of various electronic packages such as the above are shown and described in the following documents:
Peterson et al
Lee et al
Hsiao et al
Gedney et al
Fielchenfeld et al
Jacobs et al
Appelt et al
Nakao et al
Foreign Patent Documents
In order to increase the operational characteristics of such modules, the addition of more than one chip to the upper surface of a chip substrate has been considered. However, due to the operating temperatures of such added chips, especially if placed in a closely spaced orientation, a much higher temperature compensating substrate material, ceramic, has usually been required, especially when the substrate having the chips is to be mounted on and coupled to an organic substrate such as a typical PCB. Examples are described in the following IBM Technical Disclosure Bulletins (TDBs):
Multi Chip Cooling Plate
Simultaneous Chip Placement -
High Performance Multi-Chip
Low-Cost, High-Power, Multi-Chip
Thermally Conductive Substrate
Mounted Multi-Chip Module Cap
The use of ceramic, however, poses many problems, a primary one of which is handling. Ceramic is a relatively brittle material capable of cracking and chipping if handled improperly, especially during manufacture and shipping. Ceramic is also a relatively difficult material to process, especially to the multi-depth level where several individual layers of insulative and interconnecting conductive materials are needed to satisfy many operational requirements.
Chip carriers of non-ceramic material have been proposed, but these typically possess various drawbacks. In U.S. Pat. No. 5,574,630, for example, three chips are mounted on a substrate comprised of silica-filled polytetrafluoroethylene (PTFE) but require individual vias to pass through the carrier's entire thickness to connect to desired connections on the opposite side. Additionally, this structure in turn mandates utilization of a complex “power/ground assembly” of several layers having specific CTEs and other properties, thus resulting in a very expensive final assembly and one that is relatively difficult to construct.
Yet another non-ceramic substrate embodiment for having more than one chip thereon is described in U.S. Pat. No. 6,246,010. Unfortunately, the substrates described herein require semiconductor chips which are extremely thin (less than 100 μm, preferably less than 50 μm, and “most preferably” less than 20 μm). Understandably, such thinned chips are incapable of adequately providing the much greater operational capabilities as required by today's more powerful chips (e.g., those of the application specific integrated circuit (ASIC) variety). Typically, such chips operate at much higher temperatures than other types (e.g., those of the dynamic random access memory (DRAM) variety).
In grandparent pending application Ser. No. 10/354,000, cited above, there is defined a PCB which is capable of providing high speed interconnections between two or more components such as chips or modules (chip carriers) mounted thereon. This PCB is specifically designed to accommodate the increased operational requirements for electronic structures such as electronic modules which mount on the PCBs and are coupled together through the board's circuitry. One particular increase that this PCB accommodates is the need for higher frequency connections between the mounted components, which connections, as stated, occur through the underlying host PCB. Such connections are subjected to the detrimental effects, e.g., signal deterioration, caused by the inherent characteristics of such known PCB wiring. For example, signal deterioration is expressed in terms of either the “rise time” or the “fall time” of the signal's response to a step change. The deterioration of the signal can be quantified with the formula (Zo*C)/2, where Zo is the transmission line characteristic impedance, and C is the amount of the via capacitance. In a wire having a typical 50 ohm transmission line impedance, a plated through hole via having a capacitance of 4 pico farad (pf) would represent a 100 pico-second (ps) rise-time (or fall time) degradation, as compared to a 12.5 ps degradation with a 0.5 pf buried via of the present invention, as discussed below. This difference is significant in systems operation at 800 MHz or faster, where there are associated signal transition rates of 200 ps or faster.
A typical high performance PCB, prior to the ones defined in Ser. No. 10/354,000 and Ser. No. 10/394,107, has not been able to provide wiring densities beyond a certain point due to limitations imposed by the direct current (DC) resistance maximum in connections between components (especially chips). Similarly, high speed signals demand wider lines than normal PCB lines to minimize the “skin effect” losses in long lines. To produce a PCB with all wide lines would be impractical, primarily because of the resulting excessive thickness needed for the final board. Such increased thicknesses are obviously unacceptable from a design standpoint.
Various PCBs are described in the following documents:
J. Kahlert et al
R. Conn et al
J. Gulick et al
S. Lociuro et al
J. Hutchison et al
G. La Rue
S. Ramey et al
K. Bovensiepen et al
D. Anstrom et al
R. Garrett et al
Foreign Patent Document
The teachings of these documents are incorporated herein by reference.
The unique characteristics of the PCBs in Ser. No. 10/354,000 and Ser. No. 10/394,107 allow it to be able to assure high frequency connections while still utilizing relatively standard PCB manufacturing processes to produce the final structure. In these pending applications, incorporated herein by reference, a portion of the PCB is dedicated to utilizing relatively wider lines than the remaining, lower portion of the PCB, which includes lines and spacings known in the PCB field.
The use of such a structure or the like or a similar substrate of a material other than ceramic or not possessing the severe drawbacks of previous non-ceramic materials as mentioned above and which is capable of providing high speed or other effective coupling between two or more chips (especially high temperature chips such as ASIC chips) on one surface thereof as defined herein, yet which can then be directly electrically coupled to a second underlying substrate such as a typical PCB to also couple said chips to the PCB's circuitry, is believed to constitute a significant advancement in the art.
It is, therefore, a primary object of the present invention to enhance the art of chip carriers including more than one chip as part thereof, known in the ceramic substrate art also as multi-chip electronic packages (or modules).
It is another object of the invention to provide such a package which assures high speed connections between the chips thereon, while attaining effective electrical coupling with the underlying circuitized substrate (e.g., PCB) on which one or more of the carriers of the invention may be mounted.
It is a further object of the invention to provide such a package which is capable of providing such connections for high temperature chips such as those of the ASIC variety, while assuring a minimum of substrate upper surface area is utilized.
It is still another object of the invention to provide such a package which can be produced in a cost effective manner while assuring a final structure of robust construction.
Further, it is another object of the invention to provide a package-substrate assembly utilizing the package of the invention as part thereof, the assembly thus benefiting from the unique advantages of the multi-hip carrier defined herein.
Finally, it is an object of the invention to provide a method of making an electronic package including a chip carrier and plurality of chips mounted on one surface thereof, which method can be completed in a facile and relatively inexpensive manner, thus resulting in a final end product of reduced cost.
According to one aspect of the invention, there is provided a multi-chip electronic package comprising an organic, laminate chip carrier including a plurality of electrically conductive planes spacedly positioned therein and separated by respective layers of dielectric material, the chip carrier including a plurality of electrical contacts on a first surface thereof and a plurality of electrical conductors on a second surface thereof, selected ones of the electrical contacts being electrically coupled to selected ones of the electrical conductors, and first and second semiconductor chips positioned on the first surface of said organic, laminate chip carrier in a stacked orientation, each semiconductor chip electrically coupled to selected ones of the electrical contacts.
According to another aspect of the invention, there is provided a method of making a multi-chip package wherein the method comprises the steps of providing an organic, laminate chip carrier having first and second surfaces and including a plurality of electrically conductive planes spacedly positioned therein and separated by respective layers of dielectric material, providing a plurality of electrical contacts on the first surface of the organic, laminate chip carrier, providing a plurality of electrical conductors on the second surface of the organic, laminate chip carrier, selected ones of the electrical contacts being electrically coupled to selected ones of the electrical conductors, and positioning first and second semiconductor chips on the first surface of the organic, laminate chip carrier in a stacked orientation and electronically coupling the first and second semiconductor chips to the selected ones of the electrical contacts.
According to a third aspect of the invention, there is provided an electronic package assembly which includes a circuitized substrate including a plurality of electrically conductive members thereon, an organic laminate chip carrier including a plurality of electrically conductive planes spacedly positioned therein and separated by respective layers of dielectric material, the chip carrier including a plurality of electrical contacts on a first surface thereof and a plurality of electrical conductors on a second surface thereof, selected ones of the electrical contacts being electrically coupled to selected ones of the electrical conductors, first and second semiconductor chips spacedly positioned on the first surface of the organic, laminate chip carrier in a stacked orientation and electrically coupled to selected ones of the electrical contacts, and a plurality of electrically conductive elements electrically connecting the selected ones of the electrical conductors on the second surface of the organic, laminate chip carrier to respective ones of the electrically conductive members on the circuitized substrate.
For a better understanding of the present invention, together with other and further objects, advantages and capabilities thereof, reference is made to the following disclosure and appended claims in connection with the above-described drawings. It is understood that like numerals will be used to indicate like elements from FIG. to FIG.
As stated above, the term “high speed” as used herein is meant signals of high frequency. Examples of such signal frequencies attainable for the multilayered chip carriers and circuitized substrates (e.g., PCBs) defined herein and as produced using the methods taught herein include those within the range of from about 3.0 to about 10.0 gigabits per second (GPS). These examples are not meant to limit this invention, however, because frequencies outside this range, including those higher, are attainable. As further understood from the following, the carrier products produced herein may be formed of at least two separate multilayered portions (subassemblies) which have themselves been formed prior to bonding to each other. At a minimum, each of these separate portions will include at least one dielectric layer and one conductive layer, with most likely embodiments including several layers of each as part thereof. Examples are provided below and are just that (only examples) and the numbers of layers shown and described are not meant to limit the scope of this invention.
The products as defined herein are particularly adapted for use in what can be termed “information handling systems”. By the term “information handling system” as used herein shall mean any instrumentality or aggregate of instrumentalities primarily designed to compute, classify, process, transmit, receive, retrieve, originate, switch, store, display, manifest, measure, detect, record, reproduce, handle or utilize any form of information, intelligence or data for business, scientific, control or other purposes. Examples include personal computers and larger processors such as servers, mainframes, etc. An example is shown in
In one embodiment, carrier 2 includes an upper, high-speed portion 11 and a lower portion 12 in which signals pass at lower frequencies. A more specific example of this particular construction will be defined hereinbelow. The dielectric material for carrier 2 may be selected from a variety of known PCB dielectric materials, including known fiberglass-reinforced epoxy resin, Driclad (a registered trademark of the assignee of this invention), PTFE, Nelco 6000SI, Rogers 4300, Polyclad LD621 (see below), etc. Therefore, it does not necessarily need to be comprised of PTFE. It is also possible that carrier 2, if used in the present invention (
Chip carrier 2 may also include an internal capacitor structure therein, such as described in U.S. Pat. No. 6,370,012, also incorporated herein by reference. As defined therein, the capacitor structure is a parallel capacitor suitable for use in chip carriers or the like designed for being positioned on an underlying substrate such as a PCB. In the structure of U.S. Pat. No. 6,370,012, the capacitor preferably includes at least one internal conductive layer, two additional conductor layers added on opposite sides of the internal conductor and inorganic dielectric material (preferably an oxide layer) on the second conductor layer's outer surfaces. Alternatively, a suitable dielectric material such as berium titanate applied to the second conductive layer may be utilized. Further, the capacitor in this cited patent includes outer conductor layers atop the inorganic dielectric material to thus form a parallel capacitor between the internal and added conductive layers and the outer conductors. Further description is found in U.S. Pat. No. 6,370,012.
The above heat-sinking components serve to effectively remove the relatively high heat as produced by powerful chips such as those of the ASIC variety, as described above. The additional use of the internal thermally conductive member further assures an effective operating product which will not disrupt or result in damage to the relatively delicate solder connections formed both between the chip and carrier and, if utilized, between the carrier and underlying substrate.
The embodiment of
As mentioned, portion 20 is designed for providing high speed (high frequency) connections between chips located on the upper surface of the carrier's substrate and coupled thereto when portion 20 is formed in combination with another multilayered portion to form a final carrier. In order to provide such high speed connections, therefore, the individual signal lines in portion 20 (and 20′) preferably possess a width of from about 0.005 inch to about 0.010 inch and a thickness of 0.0010 to about 0.0020 inch. The corresponding dielectric layers each possess a thickness of from about 0.008 inch to about 0.010 inch. The material for planes 21, 25 and 27 is preferably copper, but other conductive materials are possible. The preferred dielectric material 23 is a low loss dielectric, one example being Polyclad LD621, available from Cookson Electronics, located in West Franklin, N.H. Additional materials include Nelco 6000SI, available from Park Nelco, located in Newburgh, N.Y. and Rogers 4300, available from Rogers Corporation, located in Rogers, Conn. These materials have a low dielectric constant and loss factor to provide the optimum operational capabilities for the structure. Other materials possessing dielectric loss ≦0.01; and preferably less than <0.005 would be suitable for use in both portions 20 and 20′. Again, this dielectric material need not be PTFE.
It is understood that the above thicknesses and defined materials are not meant to limit the scope of this invention, in that others are possible while attaining the desired results taught herein. It is also understood that the second portion of this structure, if used, can include the aforedefined thermally conductive member and/or internal capacitor structure therein. In one example, using the aforementioned thicknesses, widths and materials, it was possible to provide a second portion 20 (and 20′) capable of passing signals at a signal frequency within the range of from about 3 to about 10 GPS. This is also not meant to limit the invention in that higher frequencies, e.g., 12 GPS, are possible with relatively insignificant modification to one or more of the above materials, parameters, etc. The resulting overall thickness for portion 20 as defined, according to one embodiment, is about 0.140 inch.
Although it is not a necessary requirement, the aforementioned widths and thicknesses for the conductive planes and dielectric layers will normally be thicker than those for the base or first multilayered portion to which portions 20 and 20′ will be bonded. That is, the base portions will typically include much less thickness and width dimensions for the conductive planes and dielectrics used therein, such widths, thicknesses and materials being typical of those of known PCB structures used today. Thus, further description will not be necessary.
To access one or more of the outer conductive planes on each portion 20, openings 45 are provided within the outer dielectric layers 43. This is preferably done by laser or photoprinting operations known in the art. Following removal of the dielectric material, an outer conductive layer 51 is added on opposite sides of the structure in
It is understood in
For additional coupling, another layer of dielectric material 55 may also be added to cover the conductive planes 51, in which case, connection to the conductive material 51 within opening 45 would be accomplished by a similar opening and conductive material 61 in
Of further significance, the through holes 71 and 71′ can be used to electrically couple one or more of the chips to the internal wiring of the first multilayered portions 31 and 31′, respectively, thus providing a direct electrical connection between these components and the interim structure. Thus, the carrier defined herein may provide the unique capability of assuring coupling between chips on one side of the carrier in addition to coupling of these same chips to internal conductive planes of the base or first portion of the carrier's overall structure. Such dual coupling represents a significant aspect of the invention because it results in a final carrier product having greater operational capabilities than heretofore known products.
Package 111 differs significantly from those described above, however, through the unique positioning of a pair of semiconductor chips in a stacked orientation on the upper surface of carrier 300. In one example, a first, lower chip 77′ (preferably an ASIC chip) is electrically coupled to respective conductors on an upper surface of the carrier using a plurality of solder balls 79. Additionally, a second chip 77″ (preferably a memory chip) is secured to the upper surface of chip 77′, preferably using either a suitable adhesive known in the industry or, in the example illustrated in
Package 111 may also include additional, spaced, semiconductor chips 77′ also electrically coupled to the carrier's upper surface (as shown) for providing additional operational capabilities for the instant invention. Each additional chip 77′ is also preferably an ASIC chip but the invention is not limited thereto as a memory chip (e.g., DRAM or SRAM) may be used.
Second chip 77″, secured to lower chip 77′, is electrically coupled to outer conductors on the carrier's upper surface using a plurality of wirebond connections 113. Wirebond connections for coupling semiconductor chips are known and further description is not believed necessary. Of significance, however, is that the upper, second chip 77″ is wirebonded while in place atop the lower chip 77′. Thus, the lower chip is first electrically coupled using solder balls 79 to securely position it in place and form a second electrical connection with the desired electrical contacts on the carrier's upper surface. Thereafter, second chip 77″ is then adhesively bonded and, uniquely, wirebonded such that the second chip's contact sites 115 are coupled to the respective contacts using connections 113. Finally, a quantity of encapsulant 14′ (shown in phantom) is then positioned over the stacked chip arrangement and serves to protect the arrangement in the manner described above for encapsulant 14 (
Although only one large solder ball 99 is shown for connecting package 111 to PCB 10, it is understood that each of the solder balls 99 are similarly coupled to PCB 10.
Thus, one or both of the semiconductor chips in the stacked arrangement may be coupled indirectly to PCB 10 in addition to also being coupled to one another, if desired. Still further, the stacked chip arrangement may be coupled to one or more of the adjacent chips 77′. The result is an electronic package having significant operating capabilities to uniquely couple several semiconductor chips to a common PCB. Although only four chips are depicted in
The partial view in
Thus there has been shown and described a multi-chip electronic package which comprises an organic, laminate chip carrier and a pair of semiconductor chips positioned on a first surface thereof in a stacked orientation. There has also been shown and described an electronic package assembly which includes the aforementioned carrier and semiconductor chips in combination with a circuitized substrate (e.g., PCB) in which a plurality of electrically conductive elements (e.g., solder balls) are used to connect the chip carrier to the substrate. Significantly, the organic, laminate chip carrier of the invention is capable of having two or more semiconductor chips electrically coupled thereto which may be coupled together and/or coupled to electrical conductors on the undersurface (opposite side) of the carrier. Of further significance, these chips may be coupled in a high-speed manner so as to assure higher frequency signal passage therebetween, thus resulting in a final product structure possessing greater capabilities than heretofore known in the art. The invention is able to attain these capabilities using a carrier comprised substantially of organic laminate material such as described herein which, as defined herein, will not deform or otherwise be harmed as a result of the relatively high temperature operation of the semiconductor chips during package operation and positioning on the desired underlying circuitized substrate. The chip carrier may in turn thus be comprised of at least two portions formed in accordance with the teachings herein. Additionally, the carrier may include an internal capacitor structure such as defined and/or a thermally conductive member as part thereof designed to specifically prevent separation (disconnection) between the respective solder balls which form the connections between at least one of the chips and carrier and those, if utilized, between the undersurface of the carrier and the corresponding substrate. The invention as defined herein thus possesses many significant advantages over known chip carriers of the multi-chip variety, while utilizing a substantially organic laminate body as a main portion thereof. The method defined herein for assembling this structure can also be conducted using many known PCB procedures and thus at a relatively lower cost than other processes used to form carriers of this type, particularly those made primarily of ceramic material.
While there have been shown and described what are at present the preferred embodiments of the invention, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims.
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|U.S. Classification||361/719, 361/810, 438/109, 257/E25.011, 257/706, 438/122, 257/E23.007, 257/707, 257/723, 257/E23.173, 361/780, 257/777, 257/E23.062|
|International Classification||H01L23/31, H05K1/11, H05K7/06, H01L23/34, H05K3/46, H01L25/065, H01L23/538, H01L25/18, H05K1/02, H05K7/20, H01L25/07, H01L25/04, H01L23/14, H01L23/498|
|Cooperative Classification||H01L2924/18161, H01L2224/85399, H01L2224/05599, H01L2224/45099, H01L2924/181, H01L2924/00014, H01L24/73, H01L2924/12042, Y10T29/49144, Y10T29/49155, Y10T29/49133, H01L2224/16235, H01L24/48, H01L2924/01019, H01L2225/06558, H01L2924/01057, H01L2924/19041, H01L25/0652, H01L25/0655, H01L2224/16237, H01L2224/48227, H01L23/5383, H01L2924/16195, H01L2924/15311, H01L2224/32145, H01L23/49822, H05K1/024, H01L2924/3011, H01L2924/12044, H01L2924/1433, H01L25/18, H01L21/563, H01L23/3128, H01L2224/48091, H05K2201/09536, H01L25/50, H01L2224/73204, H01L2924/14, H01L23/145, H01L2224/73253, H05K3/4623, H01L2224/48472, H01L2224/73265, H05K1/113, H05K2201/096, H05K3/4688, H01L2924/3025, H01L2924/01078, H05K2203/061, H01L2224/16225, H01L2224/32225, H01L2924/19105, H01L2224/32245, H05K2201/10378, H01L2924/12041|
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